Commodity Production Costs Report

Cyclohexanone Production from Phenol

Cyclohexanone Operating Costs & Plant Construction Costs

160 kta United States-based plant | 107 Pages | Issue B | Q3 2024
Starting at $799 USD | See Report Editions Prices

This report approaches the economics of producing Cyclohexanone from phenol. In the examined process, phenol undergoes a hydrogenation reaction in the liquid phase, in the presence of a palladium-based catalyst, yielding Cyclohexanone. The analysis is based on a plant located in the United States.

The report provides a comprehensive study of Cyclohexanone production and related Cyclohexanone production cost, covering three key aspects: a complete description of the Cyclohexanone production process examined; an in-depth analysis of the related Cyclohexanone plant capital cost (Capex); and an evaluation of the respective Cyclohexanone plant operating costs (Opex).

The Cyclohexanone production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Cyclohexanone plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Cyclohexanone plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.

Key reference(s): ?

Cyclohexanone Production Cost Report Process Schematic

The process is comprised of three main sections: (1) Phenol Purification; (2) Hydrogenation and (3) Cyclohexanone Purification.

Phenol Purification. First fresh phenol is contacted with a solution of caustic soda and a sequestrating agent to remove metallic impurities that would be detrimental for the hydrogenation catalyst. This phenol mixture is then subjected to a two-step distillation system, producing a purified phenol stream that is directed to the hydrogenation reactor and a heavies waste stream.

Hydrogenation. Fresh hydrogen is first compressed to the hydrogenation reaction pressure and then fed to the first hydrogenation reactor alongside the purified phenol stream from the purification section. The hydrogenation is conducted in three reactors in series, in liquid phase, at mild pressure and catalyzed by palladium supported on carbon. Hydrogen is fed in excess to ensure maximum conversion of the phenol. The off-gas from the reactor is then sent to a scrubber where it is contacted against water before its disposal.

Cyclohexanone Purification. The liquid output from the hydrogenation reactors is first sent to centrifuges that are going to separate a cyclohexanone-rich liquid phase, from a the solid catalyst, that is in turn recycled to the hydrogenation reactors. The liquid stream is then subjected to a final distillation step that aims to remove traces of cyclohexanol and other heavier byproduct contaminants from the product stream. Purified Cyclohexanone is recovered as the top product of the distillation column.

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  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
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 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • Plant Cost Breakdowns
  • Plant Capacity Assessment
  • Process Flow Diagrams
  • Costs in Different Countries Add-on
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  • 107 Pages | 34 Tables | 22 Images
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Content Highlights

Plant Capital Cost Summary

Summary outlining the capital cost required for building the Cyclohexanone production plant examined.

Plant Capital Cost Details

Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements.

Plant Cost Breakdowns

Breakdown of Cyclohexanone process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline.

Operating Costs Summary

Summary presenting the operating variable costs and the total operating cost of the Cyclohexanone production plant studied.

Operating Cost Details

Detailing of utilities costs, operating fixed costs and depreciation.

Plant Capacity Assessment

Comparative analysis of capital investment and operating costs for different Cyclohexanone plant capacities.

Production Process Information

Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL).

Process Consumptions

Raw materials and utilities consumption figures, by-products credits, labor requirements

Process Diagrams

Process flow diagrams (PFD), equipment list and industrial site configuration

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